Packaging arrangement

ABSTRACT

A packaging arrangement for packaging products, such as contact lenses, in packages such as blister packs. The packaging arrangement includes a rotary index table defining on its upper surface a plurality of identical, radially-oriented support pallets, equally spaced apart around the rotary index table. Each support pallet is designed to support an array of individual package bases thereon, and is sequentially rotated to stop at angularly spaced radial positions in the rotary packaging machine. At a first radial position, the rotary packaging station receives blister package bases, each having a product deposited therein, and places the package bases in the support pallet then at the first radial position. At subsequent radial positions, the rotary packaging machine verifies the presence and alignment of each package base, deposits a fixed dosage of saline solution into each package base, optionally verifies that a fixed dosage of saline solution has been deposited in each package base, places a marked laminated cover over the package bases, heat seals the laminated cover to the package bases, verifies the proper positional placement of the laminated cover on the package bases, and finally unloads the completed blister packs from the rotary packaging station, for subsequent processing such as sterilization and secondary packaging.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a packaging arrangement forpackaging products, such as contact lenses, in packages such as blisterpacks. More particularly, the subject invention pertains to a packagingarrangement having a movable support base, such as a rotary index table,defining on its upper surface a plurality of identical support pallets,equally spaced apart along the movable support base. Each support palletis designed to support an array of individual package bases thereon, andis sequentially stopped at spaced positions in the packagingarrangement. At a first position, the packaging arrangement receivesblister package bases, each having a product deposited therein, andplaces the package bases in the support pallet then at the firstposition. At subsequent positions, the packaging arrangement verifiesthe presence and alignment of each package base, deposits a fixed dosageof saline solution into each package base, optionally verifies that afixed dosage of saline solution has been deposited in each package base,places a marked laminated cover over the package bases, heat seals thelaminated cover to the package bases, and finally unloads the completedblister packs from the packaging arrangement, for subsequent processingsuch as sterilization and secondary packaging.

2. Discussion of the Prior Art

The prior art discloses the use of rotary index tables and also linearconveyor arrangements in packaging equipment, the packaging of contactlens in saline solution, and the checking of various packages by avariety of optical probes. Moreover, the prior art also discloses heatsealing lids or covers to container bases, but in the prior art methodsof heat sealing, the temperature of the sealing heads are generallymaintained at lower temperatures, and the sealing heads are generallyapplied for longer periods of time as compared with the presentinvention. In one prior art approach, a pneumatic cylinder presses aheated sealing head against the covers being applied to package bases ona rotary index table, and a microswitch measures when the pneumaticcylinder is at the end of its power stroke, which starts a measuredheater timing period. This approach is very inaccurate as the tolerancesof all of the components, including the rotary index table, thepneumatic cylinder, and the height of the package and foil in the palletcreates timing problems.

Rather than detecting a particular physical position of the pneumaticpress as in the prior art, the present invention measures the forceapplied by a pneumatic cylinder, and activates a timer when the measuredforce reaches a threshold force, which is approximately 75% of themaximum force generated by the pneumatic cylinder. Moreover, the presentinvention positions a support below the rotary index table to ensurethat deflections under the pneumatic press are minimized.

SUMMARY OF THE INVENTION

Accordingly, it is a primary object of the present invention to providea packaging arrangement for packaging products, such as contact lenses,in packages such as blister packs.

A further object of the subject invention is the provision of apackaging arrangement having a movable support base, such as a rotaryindex table, defining on its upper surface a plurality of identicalsupport pallets, equally spaced apart along the movable support base.Each support pallet is designed to support an array of individualblister package bases thereon, and is sequentially rotated to stop atspaced positions in the lens packaging arrangement, at which a sequenceof packaging operations are performed thereon.

In accordance with the teachings herein, the present invention providesa packaging arrangement for packaging products such as contact lenses inpackages such as blister packs. The packaging arrangement includes amovable support base having on its upper surface a plurality ofidentical support pallets, equally spaced apart along the movablesupport base. Each support pallet is particularly designed to supportand align an array of individual package bases. The movable support baseis sequentially moved through substantially equal increments, with stopsbetween each sequential movement. The arrangement is such that eachsupport pallet with an array of individual package bases thereon issequentially stopped at a plurality of spaced stations in the packagingarrangement. At a first station, a robotic handling arm loads an arrayof package bases into a support pallet then at the first station. At asubsequent verification station, probes verify the presence andalignment of each package base in the support pallet. At a subsequentsaline dosing station, dosers deposit a given dosage of saline solutionin each package base. At a subsequent foil placement station, a pick andplace unit places a pair of sheets of laminated covers over the array ofpackage bases. At a subsequent heat sealing station, a heated seal headheat seals the laminated covers to the package bases. Finally, at anunloading station, an unloader arm unloads the sealed packages from thepackaging arrangement for subsequent processing.

In greater detail, at the first station, the packaging arrangementreceives individual blister package bases, each of which has a contactlens therein, and the packaging arrangement packages the contact lensesinto blister packs.

In a preferred embodiment, the movable support base comprises a rotaryindex table having on its upper surface eight identical, radially-spacedsupport pallets, positioned 45° apart around the table, each of which isparticularly designed to support an array of 2×5 package bases.

The packaging arrangement receives individual package bases, each ofwhich has a product therein, which are lined up and queued for packagingon side by side accumulator rails. The package bases are preciselypositioned on the side by side accumulator rails such that a robotichandling arm, having an array of vacuum handling cups, one for eachindividual package base, can pick up an array of package bases from theaccumulator rails and deposit them onto a support pallet at the firststation on the movable support base. Also, when the packagingarrangement is temporarily not operating, the robotic handling arm alsotransfers package bases from the accumulator rails to a buffer area.After the package bases are deposited onto one end of the side by sideaccumulator rails, first and second pneumatic cylinders advance thepackage bases to the second opposite end of the accumulator rails. Athird pneumatic cylinder at the second end of the accumulator rails thenpushes the package bases back slightly towards the first end toprecisely position the package bases at the second end of theaccumulator rails to allow the robotic handling arm to pick up an arrayof package bases.

The support pallet spaces the side of each package base a nominaldistance, in a range of 200 to 400 μmeters, from the side of eachadjacent package base in the support pallet, to prevent overlappingsides of adjacent product bases. The side by side accumulator railsaccumulate package bases in positions in which package bases directlytouch adjacent package bases. To compensate for the slight differencefrom the nominal distance between adjacent package bases in the pallet,the robotic arm, after positioning an array of package bases over apallet, releases the vacuum in each vacuum cup to allow the packagebases to fall into the support pallet. The robotic arm then raises andlowers the array of suction cups slightly to tap each package base intoa properly aligned position in the support pallet. Each package baseincludes a rounded product cavity and alignment notches on oppositesides thereof. The support pallet defines a rounded cavity for receivingeach product cavity of each package base and alignment rods which fitinto the alignment notches on the package base.

At the verification station, probes verify the presence of each packagebase in the array of package bases supported by the pallet. Theverifying probes include an array of fiber optic probes positioned abovethe array of package bases, with each fiber optic probe illuminating apackage base, and then detecting radiation reflected therefrom to verifythe presence of a package base in the support pallet. In greater detail,each fiber optic probe comprises a dual optical fiber arrangement inwhich one optical fiber carries light to illuminate the package base,and a second optical fiber carries light reflected from the package baseto a photodetector. Moreover, at least one alignment probe verifies thealignment of the packaging bases in the support pallet to check that nopackage bases are skewed or tilted in the support pallet. Each alignmentprobe includes a through-beam detector which directs a beam of lightalong the length of and just above a column of package bases supportedin the pallet to a detector at the other end of the column, such that apackage base which is skewed or tilted in the pallet interrupts thethrough beam, and the photodetector at the other end of the through beamso indicates.

At the saline dosing station, a pivotable arm supports an array ofdosing tubes, each of which is supplied by a separate dosing pump todeposit a precise dosage of saline solution into each package base, suchthat each contact lens is immersed in saline solution. A pump cart ispositioned adjacent to the saline dosing station and mounts thereon thedosing pumps and a reservoir of saline solution for the dosing pumps.Periodically, the support arm is rotated to one side to position thedosing tubes over a collection pan, and the reservoir in the pump cartis refilled. Each pump is cycled several times, with the discharge fromthe dosing tubes being collected in the collection pan, to compensatefor evaporation of saline solution and to ensure that the proper dosageamount is provided.

Moreover, optionally after the saline dosing station, at a subsequentdosing verification station, an array of sensors verifies that a givendosage (level of solution) of saline solution has been deposited intoeach package base.

At the foil placement station, a foil pick and place unit, having anarray of suction cups, lifts and places a pair of sheets of laminatedcovers over the array of package bases.

At the heat sealing station, an electrically heated seal head is pressedby a pneumatic cylinder against the laminated covers on the packagebases. A thermal transducer measures the temperature of the seal head tomaintain the temperature in a range from 210°-265° C. An in-line loadcell measures the force generated by the pneumatic cylinder, and when apredetermined force is reached, which is a percentage of a possiblemaximum force, a timer is initiated. The timer times a relatively shorttime period of approximately 0.4 to 1.4 seconds, after which thepressure in the pneumatic cylinder is released, thereby forming a sealbetween each laminated cover and package base which is both detachableand consumer friendly. The predetermined force is a given percentage,e.g., 60-75%, of a maximum force that the pneumatic cylinder is capableof generating.

The rotary index table must be maintained in a substantially levelposition for the operations performed thereon, and is reinforced underthe heat sealing station to withstand the forces imparted thereto by thepneumatic sealing cylinder. The reinforcement is provided by a block ofdurable plastic material, such as a Teflon® type of plastic, placed ontop of a support positioned beneath the rotary index table at thepneumatic cylinder. The support block is in constant contact with thebottom of the rotary index table to ensure that the deflection of therotary index table by the pneumatic cylinder is minimal. Alternatively,a pneumatically actuated movable support can be positioned in contactwith the bottom of the rotary index table prior to actuation of thepneumatic cylinder driving the heated seal head, and be removed fromcontact with the bottom of the rotary index table subsequent toactuation of the pneumatic cylinder.

At the unloading station, a pneumatically driven handling arm, having avacuum suction cup for each individual package, lifts the array ofpackages from the support pallet, and deposits the array of packages atan output position. The handling arm incorporates thereon a precisionsensor plate having a plurality of photoelectric sensors which examinethe outer edges of each sheet of laminated covers on the array ofpackages to determine if a sheet of laminated covers is skewed relativeto the array of packages. The photoelectric sensors are preferablypositioned at the corners of the expected position of the sheet oflaminated covers on the array.

The present invention also provides a method of heat sealing a laminatedtop cover to a plurality of individual package bases to create a sealedpackage with a seal which is durable, to survive subsequent packagingoperations such as sterilization, and yet consumer friendly in that aconsumer can easily separate and open the sealed package. Pursuant tothe method, a laminated sealing cover is placed over an array ofindividual, unconnected package bases. A seal head is heated to maintainthe temperature thereof in a range from 210°-265° C., and the heatedseal head is pressed by a pneumatic cylinder against the laminatedcovers on the package bases. In greater detail, the force generated bythe pneumatic cylinder is measured by an in-line load cell, and a timeris initiated when a predetermined force is reached. The timer times arelatively short time period of approximately 0.4 to 1.4 seconds, afterwhich the pressure in the pneumatic cylinder is released, therebyforming a seal between each laminated cover and package base which isboth detachable and consumer friendly. The array of individual packagebases is supported in a pallet, wherein the support pallet spaces theside of each package base a nominal distance, in the range of 200 to 400μmeters, from the side of each adjacent package base in the supportpallet, to prevent overlapping sides of adjacent product bases, and toprovide for each separation of individual packages. Each package base isprovided with a rounded product cavity and alignment notches on oppositesides thereof, and the support pallet is provided with a rounded cavityfor receiving each product cavity of each package base and alignmentrods which fit into the alignment notches on each package base.

The present invention also provides a method of packaging in which anarray of individual, unconnected package bases is placed in a supportpallet by a robotic handling arm, having a suction cup for each packagebase. The support pallet spaces the side of each package base a nominaldistance, in the range of 200 to 400 μmeters, from the side of eachadjacent package base in the support pallet, to prevent overlappingsides of adjacent product bases, and to provide for easy separation ofindividual packages. A sheet of laminated top covers is placed over thearray of individual package base, and the laminated top covers aresealed to the array of individual package bases. In greater detail, thepackage bases are initially in positions in which they directly touchadjacent package bases. To compensate for the slight difference inspacing from the nominal distance between adjacent package bases in thesupport pallet, the robotic arm, after positioning an array of packagebases over a pallet, releases the vacuum in each vacuum cup to allow thepackage bases to fall into the support pallet. The robotic arm thenraises and lowers the array of suction cups slightly to tap each packagebase into a properly aligned position in the support pallet.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing objects and advantages of the present invention for apackaging arrangement may be more readily understood by one skilled inthe art with reference being had to the following detailed descriptionof several preferred embodiments thereof, taken in conjunction with theaccompanying drawings wherein like elements are designated by identicalreference numerals throughout the several views, and in which:

FIG. 1 is a schematic top plan view of a rotary packaging arrangementconstructed pursuant to the teachings of the present invention;

FIG. 2 is a top plan view, similar to FIG. 1, of one designed embodimentof a rotary packaging arrangement constructed pursuant to the teachingsof the subject invention;

FIG. 3 is a front elevational view of the designed embodiment of arotary packaging arrangement illustrated in FIG. 2;

FIG. 4 is a left elevational view of the designed embodiment of FIGS. 2and 3;

FIG. 5 is a top plan view of one support pallet for supporting a 2×5array of package bases on the rotary index table of the rotary packagingarrangement;

FIG. 6 is a fragmentary end view of one half of the support palletillustrated in FIG. 5;

FIGS. 7 and 8 are respectively perspective and top planar views of arepresentative blister package base;

FIG. 9 is an elevational view of optical probes for verifying thepresence of a packet base at each location in the 2×5 array, and alsofor checking the alignment of the packet bases in the 2×5 array toensure that no packet bases are skewed or tilted in the support pallet;

FIGS. 10 and 11 are respectively front and side elevational views of theheat sealing head and the pneumatic press therefor;

FIGS. 12 and 13 are respectively a bottom plan view and a sideelevational view of the heat sealing head and an electrical heatertherefor;

FIG. 14 is an elevational view of the pick and place unit at the packageunloading station; and

FIG. 15 is a plan view of the sensor mounting arrangement for a skewfoil detector mounted in the pick and place unit of FIG. 14.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to the drawings in detail, FIG. 1 is a schematic plan view ofa packaging arrangement 10 constructed pursuant to the teachings of thepresent invention, for packaging products, such as contact lenses, intopackages such as blister packs. The packaging arrangement is illustratedas a rotary packaging machine having a plurality of radially spacedstations therearound. However, linear packaging arrangements havinglinear conveyor lines with linearly spaced stations therealong are alsocontemplated in alternative embodiments of the present invention.

The rotary packaging station 10 includes a rotary index table 12 whichhas on its upper surface eight identical, radially-oriented supportpallets 14, positioned 45° apart around the table, each of which isparticularly designed to support an array of individual blister packbases 16. Each support pallet 14 with an array of individual blisterpack bases thereon is sequentially rotated to stop at eight angularlyspaced radial positions in the lens packaging machine, illustrated inFIG. 1 as POS.1 through POS.8.

Each blister package base 16, as represented in further detail in FIGS.6, 7 and 8 of the drawings, includes a planar, essentially rectangularlyshaped flange 18 having an integral angularly depending wall portion 20at one end thereof. A cavity 24 is formed offset towards an oppositeedge 22 of the flange 18, which is of an essentially semisphericalconfiguration, generally in conformance with the curvilinear shape of acontact lens 26, FIG. 8, adapted to be stored therein in a sealedcondition while immersed in a suitable sterile aqueous solution. Theheight of the angled wall portion 20 depending from the planar flange 18is somewhat analogous to the height or depth of the cavity 24 containingthe contact lens, as can be ascertained more clearly from FIGS. 6 and 7of the drawings. Each package base further includes depending legs 28 ateach corner of side 22, opposite to the side with depending wall portion20, and alignment notches 30 on opposite sides of the planar flange 18.Each support pallet 14 defines a rounded cavity 32 for receiving eachproduct cavity 24 of each package base, alignment rods 34 which fit intothe alignment notches 30, and insets 36 which receive the depending legs28 of adjacent package bases 26, as illustrated best in FIG. 5.

Each blister pack base 16 may be a shaped injection-molded plasticstructure, which may be constituted of polypropylene, of generally rigidor semi-rigid configuration. A lid is adapted to be secured or bonded,such as by heat sealing to the flange 18 surfaces around theproduct-receiving cavity. Each lid may comprise a multi-layered foillaminate, as disclosed in U.S. patent application Ser. No. 08/106,386,filed Aug. 13, 1993 now abandoned. The metallic foil laminate preferablyincludes a polypropylene bottom layer which is adapted to be bonded tocontiguous sealing surfaces on the injection-molded shaped plasticpackage base, as by heat sealing or the like, to form a completepackaging structure as is well known in the packaging technology. A"blister package" of this type is disclosed, for example, in U.S. Pat.No. 4,691,820, commonly assigned to the assignee of this application.Through the intermediary of thermal transfer printing, appropriatelyvariable and changeable printed data are imparted to an exterior surfaceof the foil laminate. When the laminate is severed into lid-forminglabels for respective packages, the data may consist of suitablechangeable lot numbers, expiration dates, and other physical datarepresentative of the specific product housed in the package, forinstance, data with regard to the power of a contact lens which ispackaged in a cavity of the blister pack while immersed in a suitableprotective sterilized saline solution.

Referring to FIG. 1, at a first radial position designated POS 1, therotary packaging station receives blister package bases 16, each havinga contact lens 26 deposited therein, and places the package bases in thesupport pallet 14 then at the first position.

The lens packaging station receives individual blister package bases,each of which has a contact lens therein, which are lined up and queuedfor packaging on two side by side accumulator rails 44. In order tosuccessfully accumulate the package bases on the accumulator rails, thepackages are held down by a vacuum supplied by a vacuum pump with apressure down to 300 mbar. The blister pack bases are initiallydeposited onto the left end of the side by side accumulator rails 44 bya further good/bad robotic arm, not illustrated. The package bases areprecisely positioned on the accumulator rails 44 such that a robotichandling arm 46, having a 2×5 array of vacuum handling cups 48, one foreach individual blister pack base, can pick up a 2×5 array of individualblister pack bases 16 and load the blister pack bases onto a pallet 14on the rotary packaging machine. Each pallet 14 is particularly designedto support and align the 2×5 array of blister packs, as described ingreater detail hereinabove. Also, when the rotary packaging station 10is temporarily shut down, as for changing foil rolls in an adjacent foilmachine, the robotic handling arm 46 also transfers package bases 16from the accumulator rails 44 to a buffer area 50. After the packagebases are deposited onto one end of the side by side accumulator rails44, two pneumatic cylinders 52 advance the package bases 16 to thesecond opposite end 54 of the accumulator rails. A third pneumaticcylinder 56 at the second end of the accumulator rails then pushes thepackage bases back slightly to the left to precisely position thepackage bases at the second end of the accumulator rails to allow therobotic handling arm 46 to pick up an array of package bases.

Each support pallet 14 has a unique design relative to prior art supportpallets, in that the package bases are nominally positioned in thesupport pallet with a greater separation, in the range of 200 to 400μmeters, between the shoulders of adjacent package bases, with theseparation being provided to prevent a "shingling" effect in which ashoulder of one package base overlies a shoulder of an adjacent packagebase. The greater separation also aids in subsequent separation of theresultant adjacent blister packs. The support pallet 14 spaces the sideof each package base 16 a nominal distance, in the range of 200 to 400μmeters, from the side of each adjacent package base in the supportpallet, to prevent overlapping edges of adjacent product bases. However,the side by side accumulator rails 44 accumulate package bases 16 inpositions in which package bases directly touch adjacent package bases16, as illustrated in FIG. 1. To compensate for the slight differencefrom the nominal distance between adjacent package bases in the pallet,the robotic arm 46, after positioning an array of package bases over apallet 14, initially releases the vacuum in each vacuum cup 48 to allowthe package bases to fall into the support pallet 14. The robotic arm 46then raises and lowers the array of suction cups 48 slightly to tap eachpackage base 16 into a properly aligned position in the support pallet14, as provided for by the rounded product cavity aligning with respectto the cavity 32, the alignment notches 30 aligning with respect to thealignment rods 34, and the legs 28 aligning with respect to the inserts36.

The rotary index table is then sequentially rotated through thesuccessive angular positions, stopping for approximately 10 seconds ateach radial station, such that all the operations as described hereincan be performed simultaneously at the successive radial stations. Atthe second angular position, a vacuum is applied beneath each cavity 32in the support pallet 14 to ensure that each package base 16 is properlypositioned therein.

At the third angular position, a 2×5 array of fiber optic probes 60,FIGS. 2 and 9, are positioned above the 2×5 array of package bases toverify the presence of each package base in the array of package basessupported by the pallet. Each fiber optic probe 60 is positionedcentrally over the open flange 18 area illustrated on the right side ofFIG. 8 of each blister package base 16, and the fiber optic probe 60illuminates each package base 16, and then detects the radiationreflected therefrom to verify the presence of each blister pack base 16.The fiber optic probes 60 can be of a type available commercially fromKeyence, model FU-35f, utilized with an amplifier 62, model FS2-60. Eachsuch fiber optic detector probe 60 comprises a dual optical fiberarrangement in which one optical fiber carries light to illuminate theflange 18 of each package base 16 and a second optical fiber carrieslight reflected from the package base to a photodetector. Each fiberoptic probe 60 is positioned in a support plate 64 which is pivotallysupported on a column 66, such that the support plate 64 may be placedin an operative position as illustrated in FIGS. 2 and 9, or pivoted toa position not over the rotary index table 12. The amplifiers 62 can bemounted on the column 68 as illustrated in FIG. 9.

An alignment check is also made at the third angular position to checkthat no package bases 16 are skewed or tilted in the support pallet 14.The alignment check is performed by two through-beam detectors, as areavailable commercially from Keyence, each of which includes a lightsource 70, FIG. 9, which directs a beam of light along the length of andjust above a 1×5 column of package bases 16 supported in the pallet 14to a detector 72 at the other end of the column. If a package base 16 isskewed or tilted in the pallet 14, it will interrupt the through beam,and the photodetector 72 at the other end of the through beam will soindicate.

At the fourth angular position, referring to FIGS. 2, 3 and 4, apivotable arm 74, pivotally supported by a column 76, supports a plate78 which holds a 2×5 array of dosing tubes 80, each of which is suppliedby a separate dosing pump 82. Each dosing tube 80 deposits a precisedosage of saline solution into the cavity 24 in each blister pack base16, such that each contact lens 26 is completely immersed in salinesolution. The rate of pumping of saline solution and the diameter ofeach dosing tube 80 is chosen such that no saline solution splashes fromany of the cavities of any of the blister packs, which is very importantas any saline solution splashed onto any sealing flange 18 surfaceswould interfere with subsequent sealing and packaging operations.

Periodically, such as every four minutes, the pivotal arm 74 carryingthe array of dosing tubes 80 swings away and a reservoir 82, shownschematically with dosing pumps 82 in FIG. 2, is resupplied with salinedosing solution. The diameter of each dosing tube 80, FIG. 4, and thepumping rate therethrough have been determined empirically, with theinternal diameter of each dosing tube 80 being approximately 1/8 inch,and the pumps 84 being positive displacement 3/8 or 1/2 inch diameterpiston metering pumps, as are available from Oyster Bay Pump Works. Theamount of saline solution pumped into each package base is 950μliters±50 μliters.

The reservoir 82 of saline solution for all ten pumps and the ten pumps84 are mounted on a pump cart 86 which is normally positioned adjacentto the position 4 station, and the pumps 84 are connected to the dosingtubes 80 by a plurality of ten flexible plastic tubes 88. Salinesolution is available in the plumbing of the building in which therotary packaging station is located to refill the reservoir. Afterapproximately every four minutes of inactivity, the support arm 74 ismanually rotated to one side to position the dosing tubes 80 over acollection pan 90 in the rotary packaging station, and each pump 84 iscycled a number (e.g., five) of times, with the discharge from the tubesbeing collected in the collection pan 90. The five cycles prime eachpump to compensate for evaporation of saline solution and to ensure thatthe proper dosage amount is provided. The frequency at which the pumpsare primed depends to an extent upon the particular industrialenvironment and temperature in which the rotary packaging station islocated.

At the fifth angular position, referring to FIGS. 2 and 3, the presenceof a measured dose (given level) of saline solution in each blister packbase is verified by a 2×5 array of liquid level detectors 92 positionedabove the 2×5 array of blister pack bases. The detectors 92 aresupported by a plate 94 which is pivotally supported on a column 96,such that the plate 94 and detectors 96 can be pivoted to a position notover the rotating index table 112. Each detector can be a reflectivesensor as is commercially available from Omron, or could be anultrasonic detector, or could be a proximity sensor or could be a fiberoptic probe, as commercially available from Keyence as model 24W-V25R,used with an amplifier, model 24W-AA1C. Each detector checks andverifies for a proper height of saline solution in each blister packbase. The verification of a measured dosage of saline solution at thefifth angular position can be considered to be optional, particularly ifthe reliability of the dosing equipment at the fourth angular positionis high.

At the sixth angular position, a pair of laminar top sheets 100, FIG. 1,is placed over the 2×5 array of package bases. Each laminar top sheetcovers a 1×5 column of bases, and has printed thereon all identificationindicia required for the final package. The laminar top sheet isprepared pursuant to the disclosure of patent application Ser. No.08/106,386, filed Aug. 13, 1993 now abandoned. The laminar top sheet isproduced by a labeling machine which extends to the right of the rotarypackaging machine as illustrated in FIGS. 1 and 2. The laminar topoutput sheet 100 of the labeling machine is placed by a foil pick andplace unit 102, illustrated schematically in FIG. 1, having an array ofsuction cups 104 to lift and place the laminar top sheet 100 over thetop of the 2×5 array of package bases.

At the seventh angular position, referring to FIGS. 10, 11, 12 and 13,the top sheet is heat sealed to the base containers of the blisterpacks. A heated seal head 110, FIGS. 12 and 13, heated by a plurality ofelectric heaters 112 (illustrated as five in the embodiment of FIG. 13and as two in the embodiment of FIG. 13) mounted in a heating plate 114.The heating plate 114 is secured to the back of the seal head 110, andis supported by a pneumatic cylinder or press 116 which presses theheated seal head 110 against the laminar top sheets 100 on the packagebases 16, which are supported by the pallet such that the foil laminateand base container flanges are squeezed between the heated seal head andthe pallet as supported by the rotary index table. The heated seal headis electrically heated, and the temperature thereof is measured bythermal transducers 118 on each side of the seal head 110 to maintainthe temperature at a high temperature, when compared to similar priorart arrangements. The temperature is maintained in a range from210°-265° C.

The heated seal head comprises a 2×5 array of cylindrical sealingelements 120, each of which secures the top laminar sheet to eachpackage base 16 with an annular seal around the cavity 24 in the packagebase 16. The pneumatic cylinder is coupled to the heated seal head by amount jack bolt 122 and cylindrical support struts 124. The supportstruts 124 are biased upwardly by springs 126, such that the heated sealhead is raised and normally biased to the upper position illustrated inFIG. 10, unless the pneumatic cylinder 116 forces it down for a sealingoperation.

In operation, the back force generated by the pneumatic cylinder ismeasured by an in-line load cell 128, and a solid state timer isinitiated when a force is reached of a given percentage, e.g., 60-75%,of the peak force of which the pneumatic cylinder is capable. The solidstate timer times a relatively short time period of approximately 0.4 to1.4 seconds, after which the pressure in the pneumatic cylinder 116 isreleased. This approach, when compared with similar prior artapproaches, is very hot, very hard and very short, which creates a sealwhich is both detachable and consumer friendly.

The rotary index table 12 is preferably reinforced under the seventhangular position to withstand the heat sealing forces imparted theretoby the pneumatic cylinder 116. The rotary index table 12 must bemaintained in a substantially level position for the operationsdescribed herein. The pneumatic cylinder 116 at the seventh positionapplies a substantial force to the index table, and accordingly tomaintain the index table level, an approximately 21/2×31/2 inch supportblock 130 of a durable plastic material, similar to Teflon®, is placedon top a central support 132 and surrounding supports 134 positionedbeneath the pneumatic press. The support block 130 is in constantcontact with the rotary index table 12 to ensure that the deflection ofthe rotary index table 12 under the pneumatic cylinder 116 is minimal.Alternatively, a pneumatically actuable movable support could bepositioned in contact with the bottom of the rotary index table prior tooperation of the pneumatic cylinder driving the heated seal head, and berepositioned out of contact with the bottom of the rotary index tableafter operation of the pneumatic cylinder.

At the eighth angular position, referring to FIGS. 14 and 15, apneumatically driven handling arm 140, having a vacuum suction cup 142for each individual blister pack, lifts the 2×5 array of blister packsfrom the support pallet 14 and the rotary index table, and deposits thearray of blister packs to an output position. The handling arm 140driven by a vertical pneumatic cylinder 144 and a horizontal pneumaticcylinder, not shown--positioned behind cylinder 144, and alsoincorporates thereon a precision sensor plate 146 having a plurality ofphotoelectric sensors 148 which look at and examine the outer edges ofthe foil cover 100 on each 1×5 array of blister packs. The photoelectricsensors are preferably positioned at the corners of the expectedposition of the sheet of laminated covers on the array. Accordingly, ifthe laminated foil is properly positioned relative to the 2×5 array ofpackages, each sensor will detect the corner of the foil therebelow. Ifat least one corner detector does not detect the presence of the cornerof the laminated foil therebelow, it means that the foil cover is skewedrelative to the 2×5 array of packages, or is improperly cut short orlong.

After being deposited at the output position, the packages may then besubjected to sterilization, as in the instance when the product housedtherein is intended to be employed in a medical capacity, for example, aproduct such as a contact lens which is adapted to be packed in asterile saline solution and sealed in a compartment or cavity of thepackage. The blister packs can then be subjected to a secondarypackaging operation, such as one in which packages of 1×5 blister packsare placed in a final outer package.

It is noted that the dosing verification at angularly spaced position 4may be eliminated in some embodiments. Accordingly, in alternativeembodiments, the rotary index table could be designed with fewer (ormore) support pallets 14, positioned radially therearound, dependingupon the number of different functions to be accomplished by the rotarypackaging station. Moreover, linear packaging arrangements having linearconveyor lines with linearly spaced stations therealong are alsocontemplated in alternative embodiments of the present invention.

While several embodiments and variations of the present invention for arotary packaging station are described in detail herein, it should beapparent that the disclosure and teachings of the present invention willsuggest many alternative designs to those skilled in the art.

What is claimed is:
 1. A packaging arrangement for packaging products,comprising:a. a movable support base having on its upper surface aplurality of substantially identical support pallets, spaced equallyapart along the movable support base, each of which supports and alignsan array of individual package bases; b. means for sequentially movingthe support base through substantially equal incremental movements, withstops between each sequential movement, wherein each support pallet withan array of individual package bases thereon is sequentially stopped atspaced stations in the packaging arrangement; c. at a first station, aloader unit for loading an array of package bases in the support palletthen at the first station; d. at a subsequent foil placement station, aplacer unit for placing a sheet of laminated covers over the array ofpackage bases; e. at a subsequent heat sealing station, a heated sealhead for heat sealing the laminated covers to the package bases, andcomprising an electrically heated seal head driven by a pneumaticcylinder against the laminated covers on the package bases, which aresupported by the pallet and the support base, and wherein an in-lineload cell measures the force generated by the pneumatic cylinder, andwhen a predetermined force is detected by the in-line load cell, a timeris initiated which times a given period of time, after which pressure inthe pneumatic cylinder is released, thereby forming a seal between eachlaminated top cover and package base which is both detachable andconsumer friendly; and f. at a subsequent unloading station, an unloaderfor unloading the sealed packages from the packaging arrangement forsubsequent processing.
 2. A packaging arrangement as claimed in claim 1,wherein the unloader comprises a handling arm, having a vacuum suctioncup for each individual package, which lifts the array of packages fromthe support pallet on the movable support base, and deposits the arrayof packages at an output position.
 3. A packaging arrangement as claimedin claim 1, wherein at the first station, the packaging arrangementreceives individual blister package bases, each of which has a contactlens therein, whereby the packaging arrangement packages contact lensesinto the blister packages.
 4. A packaging arrangement as claimed inclaim 1 wherein a detector measures the temperature of the seal head tomaintain the temperature in a range from 210°-265° C.
 5. A packagingarrangement as claimed in claim 1, wherein the timer times a relativelyshort time period of approximately 0.4 to 1.4 seconds, thereby forming aseal between each laminated cover and package base which is bothdetachable and consumer friendly.
 6. A packaging arrangement as claimedin claim 1, wherein at a subsequent saline dosing station, dosersdeposit a given dosage of saline solution in each package base.
 7. Apackaging arrangement as claimed in claim 6, wherein after the salinedepositing station, at a subsequent depositing verification station, anarray of sensors verifies that a fixed dosage of saline solution hasbeen deposited into each package base.
 8. A packaging arrangement asclaimed in claim 6, wherein at the saline dosing station, a pivotablearm supports an array of dosing tubes, each of which is supplied by aseparate dosing pump to deposit a precise dosage of saline solution intoeach package base.
 9. A packaging arrangement as claimed in claim 8,wherein a pump cart is positioned adjacent to the saline dosing stationand mounts thereon the dosing pumps and a reservoir of saline solutionfor the dosing pumps, and periodically the support arm is rotated toposition the dosing tubes over a collection pan, and each pump is cycledseveral times, with the discharge from the dosing tubes being collectedin the collection pan.
 10. A packaging arrangement as claimed in claim1, wherein the movable support base is maintained in a substantiallylevel position by a reinforcement support under the heat sealing stationto withstand the forces imparted thereto by the pneumatic cylinder. 11.A packaging arrangement as claimed in claim 10, wherein the movablesupport base is reinforced by a support beneath the movable support baseat the pneumatic cylinder, to ensure that deflection of the movablesupport base by the pneumatic cylinder is minimal.
 12. A packagingarrangement as claimed in claim 1, wherein each package base includes arounded product cavity and a plurality of alignment notches on oppositesides of the package base, and the support pallet defines a roundedcavity for receiving each product cavity of each package base and aplurality of alignment rods which fit into the plurality of alignmentnotches on opposite sides of each package base.
 13. A packagingarrangement for packaging products, comprising:a. a movable support basehaving on its upper surface a plurality of substantially identicalsupport pallets, spaced equally apart along the movable support base,each of which supports and aligns an array of individual package bases;b. means for sequentially moving the support base through substantiallyequal incremental movements, with stops between each sequentialmovement, wherein each support pallet with any array of individualpackage bases thereon is sequentially stopped at spaced stations in thepackaging arrangement; c. at a first station, a loader unit for loadingan array of package bases in the support pallet then at the firststation; d. at a subsequent foil placement station, a placer unit forplacing a sheet of laminated covers over the array of package bases; e.at a subsequent heat sealing station, a heated seal head for heatsealing the laminated covers to the package bases; and f. at asubsequent unloading station, an unloader for unloading the sealedpackages from the packaging arrangement for subsequent processing,wherein the unloader comprises a handling arm which lifts the array ofpackages from the support pallet on the movable support base, anddeposits the array of packages at an output position, wherein thehandling arm incorporates thereon a precision sensor plate which definesthereon a placement position for a cover sheet relative to the precisionsensor plate, said placement position being defined by a plurality ofphotoelectric sensors mounted on the precision sensor plate around theperimeter of and surrounding the placement position, with each of theplurality of photoelectric sensors detecting an edge of a cover sheet inthe placement position, and wherein if one of the plurality ofphotoelectric sensors does not detect an edge of a cover sheet, thecover sheet is improperly positioned or is not properly sized.
 14. Apackaging arrangement as claimed in claim 13, wherein the photoelectricsensors are positioned at corners of the placement position of the coversheet.
 15. A packaging arrangement as claimed in claim 13, wherein thehandling arm has a vacuum suction cup for each individual package.
 16. Apackaging arrangement for packaging products, comprising:a. a movablesupport base having on its upper surface a plurality of substantiallyidentical support pallets, spaced equally apart along the movablesupport base, each of which supports and aligns an array of individualpackage bases; b. means for sequentially moving the support base throughsubstantially equal incremental movements, with stops between eachsequential movement, wherein each support pallet with an array ofindividual package bases thereon is sequentially stopped at spacedstations in the packaging arrangement; c. at a first station, a loaderunit for loading an array of package bases in the support pallet then atthe first station; d. at a subsequent foil placement station, a placerunit for placing a sheet of laminated covers over the array of packagebases; e. at a subsequent heat sealing station, a heated seal head forheat sealing the laminated covers to the package bases; f. at asubsequent unloading station, an unloader for unloading the sealedpackages from the packaging arrangement for subsequent processing; andg. first and second side by side accumulator rails, wherein the firstaccumulator rail accumulates and positions a first plurality ofindividual package bases, each of which has a product therein, in afirst queue line, and the second accumulator rail accumulates andpositions a second plurality of individual package bases, each of whichhas a product therein, in a separate and discrete second queue line sideby side with the first queue line, and the package bases are transferredfrom the first and second queue lines on the first and secondaccumulator rails by the loader unit to the movable support base.
 17. Apackaging arrangement as claimed in claim 16, further including meansfor precisely positioning the package bases on the first and second sideby side accumulator rails, and a robotic handling arm, having an arrayof vacuum handling cups, one for each individual package base, picks upan array of package bases and deposits the array of package bases onto asupport pallet at the first station on the movable support base.
 18. Apackaging arrangement as claimed in claim 17, wherein the robotichandling arm transfers package bases from the first and secondaccumulator rails to a support pallet positioned at the first station,and also transfers package bases between the first and secondaccumulator rails and a buffer area.
 19. A packaging arrangement asclaimed in claim 17, wherein after the package bases are deposited ontoone end of the first and second side by side accumulator rails, firstand second pneumatic cylinders advance the package bases to the secondopposite end of the first and second accumulator rails, and a thirdpneumatic cylinder at the second end of the first and second accumulatorrails then precisely positions the package bases at the second end ofthe first and second accumulator rails relative to the robotic handlingarm to allow the robotic handling arm to pick up and place an array ofpackage bases in a support pallet at the first station.
 20. A packagingarrangement as claimed in claim 17, wherein the support pallet spaces aside of each package base a nominal distance, in a range of 200 to 400μmeters, from a side of an adjacent package base in the support pallet,to prevent overlapping sides of adjacent package bases, and wherein thefirst and second side by side accumulator rails accumulate package basesin positions in which package bases directly touch adjacent packagebases, and to compensate for a slight difference in spacing from thenominal distance between adjacent package bases in the pallet, therobotic handling arm, after positioning an array of package bases over apallet, releases a vacuum in each vacuum cup to allow the package basesto fall into the support pallet, and then raises and lowers the array ofvacuum handling cups slightly to tap each package base into a properlyaligned position in the support pallet.
 21. A packaging arrangement forpackaging products, comprising:a. a movable support base having on itsupper surface a plurality of substantially identical support pallets,spaced equally apart along the movable support base, each of whichsupports and aligns an array of individual package bases; b. means forsequentially moving the support base through substantially equalincremental movements, with stops between each sequential movement,wherein each support pallet with an array of individual package basesthereon is sequentially stopped at spaced stations in the packagingarrangement; c. at a first station, a loader unit for loading an arrayof package bases in the support pallet then at the first station; d. ata subsequent foil placement station, a foil placer unit for placing asheet of laminated foil covers over the array of package bases, whereinthe foil placer unit comprises a foil pick and place unit, having anarray of suction cups, which simultaneously lifts and places at leastone sheet of laminated foil covers over the array of package bases; e.at a subsequent heat sealing station, a heated seal head for heatsealing the laminated foil covers to the package bases; f. at asubsequent unloading station, an unloader for unloading the sealedpackages from the packaging arrangement for subsequent processing; andg. at a subsequent verification station after the first station, anarray of fiber optic probes are positioned above the array of packagebases, with each fiber optic probe illuminating a package base, and thendetecting radiation reflected therefrom to verify a presence of eachpackage base in the support pallet, and further including at least onealignment probe for verifying alignment of the packaging bases in thesupport pallet to check that no package bases are skewed or tilted inthe support pallet.
 22. A packaging arrangement as claimed in claim 21,wherein the foil pick and place unit simultaneously lifts and places twosheets of laminated foil covers over the array of package bases.
 23. Apackaging arrangement as claimed in claim 21, wherein said at least onealignment probe includes a through-beam detector which directs a beam oflight along the length of and just above a column of package basessupported in the pallet to a detector at the other end of the column,such that a package base which is skewed or titled in the palletinterrupts the through beam, and the detector at the other end of thethrough beam so indicates.
 24. A packaging arrangement which verifies aproper positional placement of a cover sheet on package bases,comprising a precision sensor plate which defines thereon a placementposition for a cover sheet relative to the precision sensor plate, saidplacement position being defined by a plurality of photoelectric sensorsmounted on the precision sensor plate, positioned at corners of theplacement position of the cover sheet, with each of the plurality ofphotoelectric sensors detecting an edge of a cover sheet in theplacement position, and wherein if one of the plurality of photoelectricsensors does not detect an edge of a cover sheet, the cover sheet isimproperly positioned or is not properly sized.
 25. A packagingarrangement which verifies a proper positional placement of a coversheet on package bases, comprising a precision sensor plate whichdefines thereon a placement position for a cover sheet relative to theprecision sensor plate, said placement position being defined by aplurality of photoelectric sensors mounted on the precision sensor platearound the perimeter of and surrounding the placement position, witheach of the plurality of photoelectric sensors detecting an edge of acover sheet in the placement position, and wherein if one of theplurality of photoelectric sensors does not detect an edge of a coversheet, the cover sheet is improperly positioned or is not properlysized, and wherein the precision sensor plate is mounted on a transfermechanism.
 26. A packaging arrangement as claimed in claim 25, whereinthe transfer mechanism comprises a pneumatically driven robotic handlingarm which lifts the package bases by vacuum cups from a first positionand deposits them at a second position.